Leuze lumiflex ASM1E Quick start guide

607020-07/04 A002 Technische Änderungen vorbehalten / Subject to change without prior notice
AS-i Sicherheitsmonitor ASM1/ASM1E
Anschluss- und Betriebsanleitung
AS-i Safety Monitor ASM1/ASM1E
Connecting and Operating Instructions

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Notes on using these connection and operating instructions
This connecting and operating instructions contain information regarding the proper
and effective use of the AS-i Safety monitor ASM1 and ASM1E.
Safety precautions and warnings are designated by the symbol (see also Chap.
1.1: Explanation of symbols).
Leuze lumiflex GmbH + Co. KG is not liable for damage resulting from improper
use of its equipment. Familiarity with these instructions constitutes part of the
knowledge required for proper use.
© Reprint and reproduction, in whole or in part, only with the explicit permission of
Leuze lumiflex GmbH + Co. KG
Liebigstraße 4
D-82256 Fürstenfeldbruck, Germany
Tel. [phone] / 53 50 - 0
Fax [phone] / 53 50 - 1 90
E-Mail: [e-mail]
http://www.leuze.de

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Table of Contents
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Manufacturer Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Approval and Declaration of EC Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.4 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.5 Definition of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.6 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.7 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.8 Different types of AS-i safety monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Safety standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2.1 Application requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2.2 Residual risks (EN 292-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2.3 Areas of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.3 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.1 General technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2 Consideration of failure probability according to IEC 61508 . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3 Dimensioned drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Mounting in the switching cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5 Electrical connection ASM1/1 and ASM1E/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1 Terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2 Connection overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6 Electrical connection ASM1/2 and ASM1E/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.1 Terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.2 Connection overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7 Electrical Connection of All Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.1 AS-i bus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.2 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8 Function and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.1 Function and operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.1.1 Start-up operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.1.2 Configuration operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.1.3 Protective operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.2 Display and operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.3 Switching on the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.4 Device configuration and parameterisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.5 Technical safety documentation for the application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1 Checking for safe shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 Status Display, Errors and Error Rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.1 Status display on the device / error diagnosis on the PC . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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10.2 Troubleshooting tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.3 Error release with the "Service" button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.4 Replacing defective safe AS-i slaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.4.1Replacing a defective safe AS-i slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.4.2Replacing several defective safe AS-i slaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.5 Replacing a defective AS-i safety monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.6 What to do if you forget the password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11 Diagnostics via AS-Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.1 General procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.2 Telegrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11.2.1Diagnosis of AS-i safety monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11.2.2Diagnosis of modules, sorted according to OSSD . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.2.3Diagnosis of modules, unsorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
11.3 Example: Querying with diagnosis sorted according to OSSD . . . . . . . . . . . . . . . . . . . . . 107
12 Safe Bus Systems with AS-Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
12.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
12.2 Transmission-specific hardware structure of the bus subscribers . . . . . . . . . . . . . . . . . . . 110
12.3 Safe telegram structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
12.4 Measures against transmission errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
12.5 Determining the residual error probability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
12.6 Commissioning/repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
12.7 Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12.8 Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12.9 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
13 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
14 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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1 General Information
1.1 Explanation of symbols
The symbols used in this connecting and operating instructions are explained below.
Attention!
Pay attention to passages marked with this symbol. Failure to observe the provided
instructions could lead to personal injury or damage to equipment.
Notice!
This symbol indicates text which contains important information.
1.2 Manufacturer Certificates
The manufacturer of the AS-i Safety Monitor ASM1, ASM1E, Leuze lumiflex GmbH +
Co. KG, in D-82256 Fürstenfeldbruck possesses a certified quality assurance system
in accordance with ISO 9001.
The AS-i Safety Monitor ASM1, ASM1E was developed and manufactured considering
of valid European standards and guidelines.
1.3 Approval and Declaration of EC Conformity
Notice!
The corresponding Declaration of Conformity and prototype test certificate can be
found at the end of this connecting and operating instructions.
EU Prototype Testing (Europe) USA
TÜV IndustrieService GmbH
Geschäftsfeld ASi
Automation, Software und Informations-
technologie
Am Grauen Stein
51105 Köln, Germany
UL and CSA
*) in progress
**

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1.4 Standards
• Draft: Fundamentals for the testing and certification of "Bus systems for the
transmission of safety-relevant messages"
• DIN V VDE 801 – Fundamentals for computers in systems with safety tasks
• EN 954-1 – Safety of machines – safety-related elements of control systems
• EN 50295 – Low-voltage switching devices; control-system and device interfaces;
actuator sensor interface (AS-i)
• EN 60204-1 – Safety of machines – electrical equipment for machines – Part 1:
general requirements
• EN 60947-5-1 – Low-voltage switchgear and controlgear – Part 5-1: control
devices and switching elements; electromechanical control devices
• EN 61496-1 – Non-contact safety guards
1.5 Definition of terms
Output switching element (safety output) of the AS-i safety monitor
Element activated by the logic of the monitor which is able to safely switch off the
downstream control elements. The output switching element may switch to or remain in
the ON state only when all components are functioning as intended.
Output circuit
Consists of the two logically connected output switching elements.
OSSD
The safe AS-i components and functional components assigned to an output circuit.
They are responsible for releasing the machine element which generates the hazar-
dous movement.
Integrated slave
Component in which sensor and/or actuator functions are grouped together with the
slave to form a unit.
Configuration operation
Operating state of the safety monitor in which the configuration is loaded and checked.
Master
Component for data transmission which controls the logical and temporal behaviour on
the AS-i line.
External device monitoring circuit (contactor monitoring)
The external device monitoring circuit allows the switching function of the contactors
connected to the AS-i safety monitor to be monitored.
Safety output
See output switching element.
Safe input slave
Slave which reads in the safe ON or OFF state of the connected sensor or command
device and transmits it to the master or safety monitor.

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Safe slave
Slave for connecting safe sensors, actuators and other devices.
Safety monitor
Component which monitors the safe slaves and the correct functioning of the network.
Slave
Component for data transmission; the master cyclically requests these components by
their BUS addresses. Only then do they generate an answer.
Standard slave
Slave for connecting non-safe sensors, actuators and other devices.
Synchronisation time
The maximum permissible temporal offset between the occurrence of two events which
are dependent on one another.
1.6 Abbreviations
AS-i Actuator Sensor AS-Interface
BWS Non-contact safety guard
CRC Cyclic Redundancy Check
I/O Input/Output
EDM External Device Monitoring
EMC Electromagnetic compatibility
ESD Electrostatic Discharge
PELV Protective Extra-Low Voltage
PFD Probability of Failure on Demand
PLC Programmable Logic Control

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1.7 Brief description
The actuator-sensor interface (AS-i) has established itself as a system for networking
primarily binary sensors and actuators at the lowest level of the automation hierarchy.
The high number of installed systems, the ease of use and the reliable operating
behaviour also make the AS-i interesting in the area of machine safety.
The safe AS-i system is intended for safety applications up to Category 4 in
accordance with EN 954-1. Mixed operation of standard components and safe com-
ponents is possible.
Notice!
A brief description of the safe AS-i transmission can be found in Chapter 12 at the end
of this operating manual.
The AS-i safety monitor monitors within an AS-i system the safe slaves which have
been assigned according to the configuration specified by the user with the configura-
tion software. Depending on the device model, up to two dependent or independent
OSSDs, each with external device monitoring circuit, are available. In the event of a
stop request or a defect, the AS-i safety monitor safely switches off the system in
protective operation mode with a maximum reaction time of 40ms.
Fig. 1.7-1: Safe and standard components in an AS-i network
Multiple AS-i safety monitors can be used within an AS-i system. In this way, a safe
slave can be monitored by multiple AS-i safety monitors.
a = Standard PLC with standard
AS-i master
b = Standard I/O-module
c = Safety monitor
d = Safety E-STOP push button
e = Safety I-module
f = AS-i power supply unit
g = Safety light barrier
h = Safety light grid
i = Standard I/O-module
j = Safety position switch
a
f
g
b
i
h
cde
j

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1.8 Different types of AS-i safety monitors
The safety monitor is available in a total of four versions which differ with regard to the
functions provided by the operating software and the initial configuration.
The "Basic" and "Enhanced" functions differ as follows:
Table 1.8-1: "Basic" and "Enhanced" functions
Notice!
A detailed description of all functions can be found in the user manual for the asimon
configuration software.
Initial configuration
Features of device versions
Table 1.8-2: Features of device versions
"Basic""Enhanced"
Number of functional components at logic level 32 48
OR gates (inputs) 2 6
AND gates (inputs) – 6
Safe time function, turn-on and turn-off delay no yes
Function "button" no yes
Safety guard/module with debouncing no yes
Deactivation of functional components yes yes
Error release yes yes
Diagnosis stop yes yes
Support of A/B technology for non-safe slaves yes yes
New functional components (flip-flop, pulse with pos. edge, etc.) no yes
Dummy module (NOP) yes yes
ASM1/1 and ASM1E/1 One output circuit
ASM1/2 and ASM1E/2 Two output circuits
Functions
"Basic""Enhanced"
Number of output circuits 1 ASM1/1 ASM1E/1
2 ASM1/2 ASM1E/2